Insulating material



March 24, 1931. A. F. HILL ET Al. .1,797,263

INSULATLNG MATERIAL Filed March 25 192,8l 2 sheets-smeet 1 gnou/Hoz March 24, 1931. A. F. HILL ET AL l INSULATING MATERIAL Sheets-Sheet 2 Fi-led March 23, 19284 Patented Mar. 24, 1931 a y UNITED STATES PATENT OFFICE ALVAE F. HILL, OF ST. PAUL, MINNESOTA, .AND DENNIS C. LENIHAN, OF LE MARS,

IOWA I INsULA'rrNG MATERIAL Application led March 23, 1928. Serial No. 264,129.

This invention relaties to insulation of the frame members of buildings and containing cellular gypsum type. Insulation of this an integral and previously set and dried body type is supplied in the form of a powder of cellular-gypsum composition, the panels which is mixed with a predetermined amount being formed to permit sealing' ofthe sides of water and allowed to set in order to form of the same in place by grouting consisting 55 a solid mass. Prior to the setting the greater of a relatively small amount o'the same compart of the added moisture combines with position mixed wet and poured after the the powder, and gas is produced which forms panel vis in place in the wall or floor of a dispersed cells throughout the mass while building.

causing a large increase in volume. The Our invention also includes anovel and effi- 60 material hardens within a period of a few cient method of making solid integral panels minutes. The hardened mass will not withof.A such insulation in a protecting envelope stand severe crushing forces but has high adapted to be shipped for installation beinsulating value and may readily be cut into tween the frame members of buildings.

l5 desired shapes. Heretofore where such insu- The invention will be best understood by 65 lation has been used in the construction of reference to the accompanying drawings in buildings or the like it has been the practice which Figure 1 is a perspective view of a to fill in the space between the studding, unit or panel of our improved insulating joists or other framework with a slurry-like material; Fig. 2 is a horizontal section mixture of the powdered composition and through a: partially erected wall showing 70 water. Obviously this practice necessitates the arrangement of the insulation therein; the erection of a complete form for-a wall Fig. 3 is a vertical section through a portion comprising an outer sheathing or shell and a of aceiling with our insulation installed; spaced, inner shell or falsework, and necessi- Fig. 4 is a perspective view of a suitable mold tates moisture tight ceilings where a iioor or for forming the panels, with the cover open .75 ceiling is to be insulated. Waste of material and Fig. 5 is a vertical section taken on the often results because the mass of insulation line 5 5 of Fig. 4, but with the mold cover is unnecessarily thick. Further in many closed. cases the moisture re uired in excess of that In the drawings we have used the numeral which will combine with the powder is objec- 6 to indicate' a hardened, integral body of 80 tionable because of the difficulties attending cellular gypsum composition which is enthe subsequent drying. This excess is norx closed to form a unit or panel by an envelope mally between eight and twelveper cent of 7 Paper board on yaccount of its cheapness the water added to make the cellular comis preferred for the construction of the enposition. Notwithstanding the diiiculties velope 7 although any suitable sheet material 85 attendant upon vsecuring a tight form and in may be used. We have found `that chip drying excess moisture after the composition board of from 15 to 20 point thickness has hasset, this type of insulation is in wide desuicient strength and iexibility to meet the mand for building purposes because of its requirements of the envelope 7 The en- 4@ light weight, high lnsulating and fire proof velope is creased and folded to form a tubuf 90 qualitles and capacity to expand and set'with lar structure covering all of the longitudinal resultant sealing of` all connected spaces sides of the panel. The panel isV quadriwhlch would otherwise be left open. lateral in cross section having parallel sides It 1s the obyect of this invention to elimi- 8 and 9 .with edges 10 converging from the nate the objectionable features above pointed side 8 to the side 9 and forming equal oblique 95 O ut Whll@ I'Qtlmng the Sallent gOOd qualiangles with said sides. At the lon 'tudinal tles of such insulation. edges of the side 8 the envelope projects and More particularly, 1t 1s our object to prois folded back upon itself to form relatively vide insulation 1n the form of protected flexible flanges 11 which normally project in Y 00 panels, adapted to be secured between the continuation of the side 8.` The cellular 10 lar structure with overlapping edges 12 extending along one side.- The tube thus formed is of uniform size and shape in cross section throughout its length and may be made of any desired length depending upon the size of the panel desired. Obviously the -width and thickness of the panels may also be varied between wide limits but where they are to lit between the studding of a building with the stu-dding at the standard spacing of sixteen inches between centers, the panel is' made 14% inches acrossthe side 8 and with the flanges 11 about 1/2 inch in width, thus ,making the panel 151/4 inches over all in width. The side 9 may be made about 121/4 inches in width and for most installations we prefer a thickness of panel of about three inches.

In Fig. 2 we have illustrated the method of installing our invention between the studding of a building. As here illustrated the members 13 are the studding of a building. The outer shell of a wall is'in-dicated by the numeral 14. Assuming that'the members 13 and the shell 14 or sheathing has been erected, a panel of our insulating material may be quickly and easily secured between each pair of the members 13. Thus a panel, ofsay 6 to 10 feet in length, may b-e pressed between aA pair of the members 13 by inserting the narrow side 9 first and forcing the flanges 11 to bendlback by wedge action against the opposed faces of the members 13. As some force is required to bend the flanges 11 we prefer to apply a rigid board or other support 15 to the outer surface of the side 8 when inserting a panel. The operator merely presses upon the support 15 in forcing the panel into place. When the panel hasbeen inserted it will be evident that triangular spaces 16 are left at each longitu-dinal edge thereof. In order to fill this space and securelyihold the panel in place we now insert grouting 17. This grouting is preferably formed by mixing suitable proportions of i dry gypsum power and Water and pouring the mixture into the triangular spaces 16. This composition immediately sets after ex anding and fills all connected openings. s the amount of grouting is small compared with the insulation 6, previously dried, there is a very small excess of moisture to be .disposed of after the grouting has set. We have found thatl this excess is quickly absorbed by the surrounding structure and that the panels so secured in place have excellent insulating qualities. The panels may be fitted end to end to fill in the entire space between frame members.

. The flanges 11 perform a number of important functions. Notwithstanding the fact that the spacing of the studding or other frame members varies somewhat due to errors and unavoidable irregularities, the flexible and resilient flanges-l1 insure firm contact with the studding throughout their length. Thus these fianges -retain the insulating panels in place until the grouting 17 can be poured and a-djust themselves so as to conform to the frame members and insure the retention of the grouting 17 when it is poured in liquid state into the triangular spaces 16.

Fig'. 3 illustrates how our improved insulation may be used in a ceiling or floor. As

hereshown the numeral 19 indicates a horif flanges l1 againstthe opposed faces of the j oists 20. Triangular bars of grouting 21 are finally cast in situ by pouring the fluid mixture of `gypsum composition and water between the joists 20 and the longitudinal edges 10 of the panels. As above pointed out the fianges 11 resiliently conform to the joists 20 to insure retention of the grouting 21 when it is poured. The .insulation ma be applied to an old ceiling where there is danger of staining or otherwise injuring the decorated surface. For such use it will be seen that our invention has marked advantages over the old method of pouring a large amount of the composition upon the backing for the ceiling because the moist grouting is separated from the ceiling by the flanges 11. Even if a small amount of the grouting should leak past these flanges we have found that this is insufficient to injure the ceiling in any wa because the excess of moisture is quickly a sorbed.

A suitable mold for forming our insulation is shown in Figs. 4 and 5. VAs here shown we provide a pair of parallel and inclined side members 22 adapted to support the edges 10 of the panels and a removable bed 23 also supported in inclined, position and adapted to support the side 9 of thel insulating panel.

Longitudinal brace members "244 upon the ing the bed 23. Upon the top of the side bars 22 are secured furring strips 28 extending longitudinally thereof in parallel relation to each other. These strips are adapted to receive between them a cover 29 which is pivotiso panels are sulliciently reinforced by 1 ally Asecured at its lower end by hinges to a transverse member 81. This member 31 is rigidly secured across the ends of the members 22 and formsa closure for the lower end of the mold.

To form a panel in the mold above described an envelope 7 creased and foldedto final form is inserted as indicated in Figs. 4 and' 5 between the members 22 and withthe flanges 11 of the envelope supported upon the top of said members. The cover -29 is now closed as indicated in Fig. 5 so as to retain the flanges 11 in collapsed form and to confine or hold down the upper surface of the envelope 7. A suitable wetpmixture of gypsum composition is now poured into the open upper end of the envelope "7. hWithin' a few minutes theJ composition sets so4 that it is self sustaining and the cover 29 is opened to permit the withdrawal of the4 molded panel with its envelope. The panel is now removed together with the supporting bed 23 and placed in an oven where itis dried. When dry the A the envelope 7 to permit shipping and andling without destruction. 1

Having described our invention what we claim is new and desire to protect by Letters Patent is: l f

1. An insulating material adapted to be inserted between frame members of a building comprising, a long and relatively narrow edges of said panel anda flexible flange extending along and projecting from the outer extremity of a longitudinal edge of said panel, said flange being arranged to make contact with one of the opposed faces of said members.

`2. The insulating material specified in 4. An insulating material adapted to be inserted between frame members of a build- I material covering the longitudinal faces and side edges of said panel and formed with a flexible flange projecting from the outer ex? tremity of at least one of said side edges, said panel being adapted to fit between said frame members of a building with said offset portions and flanges forming longitudinal receptacles for grouting and a filling of grouting insaid receptacles. f

5. An article of manufacture comprising, a body of insulating material having arallel faces and a longitudinal side edge orming an acute angle with one of said faces and a flexible flange projecting from said edge at its junction with said last mentioned face and extending longitudinally of said body.

6. An article of manufacture comprising, a body of insulating material substantially enclosed with an envelope yof foldable sheet material and having portions of a longitudinal side edge offsetfinward from the -outer extremity of said edge and a flexible flange projecting outward from the outer extremity of said side edge.

In testimonyl whereof, we have'hereunto signed our names to this specification.

' ALVAH F. HILL.

DENNIS C. LENIHAN.l

sol

cla-im 1 in which the outer extremities of both longitudinal edges, of 'said envelope are formed with resilient flanges adapted to eon'- form to the opposed faces of frame members vwhen inserting between'said members.

3. An insulating material adapted to be inserted between frame'members ofa' build-` ingcomprising, a long and relatively narrow panel of cellular gypsum composition. or the like having beveled longitudinal side edges,

an envelope of foldable sheet material cover.`

' ingthe longitudinal faces and.l side edges of said panel and a `flexibleu flage'extending along a longitudinal edgeofll said panel and projecting outward from the extreme outer corner of at least one of said beveled edges,

said panel being formed to lit between frame members of a building with said flange makz: faces of said members.

ino' resilient contact with one of the opposedl 

